Autonomous remaining useful life estimation

• US 8,831,894 B2
• Filed: 11/23/2011
• Issued: 09/09/2014
• Est. Priority Date: 06/14/2004
• Status: Active Grant

• Current Assignee: Stylwan IP Holding LLC
• Original Assignee: Stylianos Papadimitriou, Wanda G. Papadimitriou
• Inventors: Papadimitriou, Wanda G., Papadimitriou, Stylianos
• Primary Examiner(s): Bui, Bryan
• Application Number:
  US13/304,136
• Publication Number:
  US 20130060487A1
• Time in Patent Office: 1,021 Days
• Field of Search: 702/34
• US Class Current: 702/34
• CPC Class Codes: G01M 5/0033 by determining damage, crack or wear
• CPC Class Codes: G07C 3/14 Quality control systems
• CPC Class Codes: G10L 15/22 Procedures used during a speech recognition process, e.g. man-machine dialogue

Abstract

The equipment comprises at least one computer and a material features acquisition system operable to detect a plurality of material features. The features are then evaluated according to rules that capture the multidiscipline knowledge of experts and are already inputted into the computer. The computer iterations are processed until an acceptable conclusion is made regarding the condition of the material under evaluation, thus alleviating the need for multidiscipline experts to examine and analyze all the material data manually.

Claims

1. A method to evaluate material comprising:

utilizing at least one computer to operate a material features acquisition system operable to detect a plurality of material features in a material under evaluation, said material features acquisition system comprising of at least one sensor with an output indicative of at least one of said plurality of material features from said material under evaluation;

repeatedly scanning said material under evaluation with said material features acquisition system to produce said output over time;

utilizing said at least one computer to evaluate said output to detect new material features and monitor previously detected material features in said material under evaluation;

programming said at least one computer to utilize said new material features and said previously detected material features to determine at least one degradation mechanism from a plurality of possible degradation mechanisms affecting said material under evaluation, and

said programming further comprising a calibration step of providing at least one material sample with at least one feature from at least one degradation mechanism and scanning said material sample and adjusting said programming of said at least one computer whereby said determination of said at least one degradation mechanism matches a known degradation mechanism of said material sample.

2. The method of claim 1, further comprising programming said computer to recommend a preventative action to inhibit said at least one degradation mechanism.

3. The method of claim 1, whereby said material comprising of at least one of aircraft, bridges, cranes, drilling rigs, frames, chemical plant components, engine components, oil country tubular goods, OCTG, pipelines, power plant components, rails, refineries, rolling stoke, sea going vessels, service rigs, structures, vessels, workover rigs, components of the above, or combinations of the above.

4. The method of claim 1, whereby said step of utilizing said new material features and said previously detected material features further comprises of a determination of a fitness-for-service of said material.

5. The method of claim 1, whereby said step of utilizing said new material features and said previously detected material features further comprises of a determination of a remaining-useful-life of said material.

6. The method of claim 1, whereby said output produced during scanning comprises of at least one of absolute value, parameter ratio, remaining ratio, coverage ratio, rate of change, feature morphology, size, density, coverage, time-dependency and combinations thereof.

7. The method of claim 1, whereby said material sample comprises a plurality of features from said at least one degradation mechanism and whereby a corresponding evaluation outcome of said material sample is known.

8. The method of claim 7, whereby said material sample comprises two or more coexisting features from one or more degradation mechanisms and whereby a corresponding evaluation outcome of said material sample is known.

9. The method of claim 1, further comprising of inducing excitation into said material under evaluation.

10. The method of claim 9, wherein said output is produced, at least in part, in response to said excitation induced into said material under evaluation.

11. The method of claim 1, wherein said at least one computer further comprises of storage whereby at least one of said output, said new material features, said previously detected material features, said at least one degradation mechanism, said at least one degradation mechanism from said calibration step and said adjusting of said programming is stored.

12. A method to evaluate material comprising:

scanning said material and detecting an output of at least one sensor, said output comprising signals indicative of at least one feature from the material under evaluation, in a time-varying electrical form;

converting said signals to a digital format producing digital signals; and

programming at least one computer to determine at least one degradation mechanism from a plurality of possible degradation mechanisms affecting said material by analyzing said digital signal;

said programming further comprising a calibration step of providing at least one material sample with at least one feature from at least one degradation mechanism and scanning said material sample and adjusting said programming of said at least one computer whereby said determination of said at least one degradation mechanism matches a known degradation mechanism of said at least one material sample.

13. The method of claim 12, further comprising programming said computer to recommend a preventative action to inhibit said at least one degradation mechanism.

14. The method of claim 12, whereby said material comprising of at least one of aircraft, bridges, cranes, drilling rigs, frames, chemical plant components, engine components, oil country tubular goods, OCTG, pipelines, power plant components, rails, refineries, rolling stoke, sea going vessels, service rigs, structures, vessels, workover rigs, components of the above, or combinations of the above.

15. The method of claim 12, whereby said step of determining at least one degradation mechanism further comprises of a determination of a fitness-for-service of said material.

16. The method of claim 12, whereby said step of determining at least one degradation mechanism further comprises of a determination of a remaining-useful-life of said material.

17. The method of claim 12, whereby said digital signal produced during said scanning comprises of at least one of absolute value, parameter ratio, remaining ratio, coverage ratio, rate of change, feature morphology, size, density, coverage, time-dependency and combinations thereof.

18. The method of claim 12, whereby said material sample comprises a plurality of features from said at least one degradation mechanism and a corresponding evaluation outcome of said material sample is known.

19. The method of claim 18, whereby said material sample comprises two or more coexisting features from one or more degradation mechanisms and whereby a corresponding evaluation outcome of said material sample is known.

20. The method of claim 12 further comprising of inducing excitation into said material under evaluation.

21. A system to evaluate material comprising of:

at least one computer;

a material features acquisition system to scan said material comprising of at least one sensor with an output to detect at least one material feature from a plurality of material features in a material under evaluation;

at least one program being executed on said at least one computer to recognize said at least one material feature from said plurality of material features and to compute a material evaluation;

a calibration sample with at least one material feature whereby the evaluation outcome of said calibration sample is known and said at least one program being adjusted whereby said computed calibration sample evaluation matches the known evaluation of said calibration sample; and

said at least one adjusted program to compute a material evaluation to determine whether said material is fit for use for a service or should be removed from use in said service.

22. The system of claim 21, whereby said material comprising of at least one of aircraft, bridges, cranes, drilling rigs, frames, chemical plant components, engine components, oil country tubular goods, OCTG, pipelines, power plant components, rails, refineries, rolling stoke, sea going vessels, service rigs, structures, vessels, workover rigs, components of the above, or combinations of the above.

23. The system of claim 21, whereby said output produced during said scanning comprises of at least one of absolute value, parameter ratio, remaining ratio, coverage ratio, rate of change, feature morphology, size, density, coverage, time-dependency and combinations thereof.

24. The system of claim 21, whereby said calibration sample comprises a plurality of material features and whereby a corresponding evaluation outcome of said material sample is known.

25. The system of claim 21, whereby said calibration sample comprises two or more coexisting material features and whereby a corresponding evaluation outcome of said material sample is known.

26. The system of claim 21 further comprising of inducing excitation into said material under evaluation.

27. The system of claim 26 wherein said output is produced, at least in part, in response to said excitation induced into said material under evaluation.

28. A system to evaluate a material, said system comprising of:

at least one computer;

a material features acquisition system comprising of at least one sensor with an output indicative of at least one of a plurality of material features from a material under evaluation;

at least one storage for said computer;

at least one program being executed on said at least one computer to evaluate said output from said material features acquisition to determine a presence of at least one degradation mechanism from a plurality of possible degradation mechanisms;

at least one calibration sample with at least one material feature from at least one degradation mechanism whereby an evaluation outcome of said at least one calibration sample is known; and

said program being adjusted whereby said calibration sample evaluation matches the known evaluation of said calibration sample.

29. The system of claim 28, further comprising said material under evaluation comprising of at least one of aircraft, bridges, cranes, drilling rigs, frames, chemical plant components, engine components, oil country tubular goods, OCTG, pipelines, power plant components, rails, refineries, rolling stoke, sea going vessels, service rigs, structures, vessels, workover rigs, components of the above, or combinations of the above.

30. The system of claim 28, further comprising said output from said material features acquisition system comprises of at least one of absolute value, parameter ratio, remaining ratio, coverage ratio, rate of change, feature morphology, size, density, coverage, time-dependency and combinations thereof.

31. The system of claim 28, further comprising said calibration sample comprises a plurality of features and whereby a corresponding evaluation outcome of said material sample is known.

32. The system of claim 28, further comprising said calibration sample comprises two or more coexisting features and whereby a corresponding evaluation outcome of said material sample is known.

33. The system of claim 28, further comprising an excitation mechanism for said material features acquisition system operable to induce excitation into said material under evaluation.

34. The system of claim 33, wherein said output is produced, at least in part, in response to said excitation induced into said material under evaluation.

35. The system of claim 28, wherein said at least one adjusted program determines at least one degradation mechanism and computes whether said material is fit for use for a service or should be removed from use in said service.